Cage spacer with roller wheel

ABSTRACT

A cage spacer for spacing a reinforcement structure apart at a predefined distance from a forming surface of a forming structure for a cementitious structure during formation of the cementitious structure therein has a bracket and a roller wheel, both constructed of a plastic material. The bracket has an attachment face and a generally opposed roller face and is connectable to the reinforcement structure with the attachment face abutting thereagainst. The roller wheel is rotatably and removably mounted in the bracket with an outer circumferential surface thereof extending from within the bracket partially beyond the roller face. The roller wheel is sized and positioned relative the attachment face for abutting and rolling of the outer circumferential surface against the forming surface at the predefined distance from the reinforcement structure, thereby spacing the reinforcement structure apart from the forming surface at the predefined distance.

CROSS REFERENCE TO RELATED APPLICATIONS

Benefit of U.S. Provisional Application for Patent Ser. No. 61/193,328, filed on Nov. 18, 2008, is hereby claimed.

FIELD OF THE INVENTION

The present invention relates to a spacer, and is more particularly concerned with a cage spacer for spacing a reinforcement structure apart from a forming surface of a forming structure during formation of a cementitious structure in the forming structure.

BACKGROUND OF THE INVENTION

Cage spacers for cement forming structures, for example a mould, for forming cementitious structures are well known in the art. Such spacers typically have a bracket having an inner face attached to and abutting against a reinforcement structure, for example a cage, with a cylindrical roller wheel, freely and rotatably mounted in the bracket with a portion of the circumference thereof extending beyond an outer side, disposed opposite the inner face of the bracket. Thus, one or more spacers may be attached to the reinforcement structure, preferably spaced apart around a perimeter thereof, with the outer facing away therefrom. The reinforcement structure may then be easily placed in a mould, or other forming structure, by rolling the reinforcement structure into the forming structure on the roller wheels. At the same time, each roller wheel is mounted on the bracket and is sized and shaped such that that the distance between the forming surface of the forming structure, against which the roller wheel abuts and rolls, and the cage, against which the inner face abuts, is equal to the desired spacing. Thus, use of the spacer also ensures that the desired spacing between the forming surface and the reinforcement structure are maintained.

Unfortunately, such conventional spacers often have metal or glass components, which may be expensive and damaged by cementitious materials such concrete or cement. Further, the roller wheels for conventional roller spacers are typically not removable or replaceable. Thus, the distance of the spacing provided by such spacers is not adjustable. Further, should the roller wheel be defective, then the entire spacer must be discarded and replaced.

Accordingly, there is a need for an improved spacer for spacing a reinforcement structure apart from a forming surface of a forming structure during formation of a cementitious structure in the forming structure.

SUMMARY OF THE INVENTION

It is therefore a general object of the present invention to provide an improved cage spacer for spacing a reinforcement structure, such as a cage, apart from a forming surface of a forming structure during formation of a cementitious structure in the forming structure.

An advantage of the present invention is that the spacer can provide an adjustable spacing at an adjustable distance for the reinforcement structure relative the forming surface.

Another advantage of the present invention is that the spacer is resistant to damage and impediment by the cementitious material of which the cementitious structure is formed.

In one aspect, the invention provides a cage spacer for spacing a reinforcement structure apart at a predefined distance from a forming surface of a forming structure for a cementitious structure during formation of the cementitious structure therein, the cage spacer comprising:

-   -   a bracket having an attachment face and a generally opposed         roller face, the bracket being connectable to the reinforcement         structure with the attachment face abutting thereagainst; and     -   a cylindrically shaped roller wheel rotatably mounted in the         bracket with an outer circumferential surface thereof extending         from within the bracket partially beyond the roller face, the         roller wheel being sized and positioned relative the attachment         face for abutting and rolling of the outer circumferential         surface against the forming surface at the predefined distance         from the reinforcement structure, thereby spacing the         reinforcement structure apart from the forming surface at the         predefined distance and enabling rolling of the reinforcement         structure into the forming structure at the predefined distance         from the forming surface, the bracket and the roller wheel being         constructed of a plastic material.

Other objects and advantages of the present invention will become apparent from a careful reading of the detailed description provided herein, with appropriate reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Further aspects and advantages of the present invention will become better understood with reference to the description in association with the following Figures, in which similar references used in different Figures denote similar components, wherein:

FIG. 1 is a top perspective view of an embodiment of a cage spacer in accordance with an embodiment of the present invention;

FIG. 2 is an exploded view of the spacer shown in FIG. 1;

FIG. 3 is a top plan view showing the spacer of FIG. 1 in use in a mould for a cementitious structure;

FIG. 4 is a sectional view, taken along line 4-4 of FIG. 3, showing the spacer of FIG. 1 in use in a mould for a cementitious structure; and

FIG. 5 is a top perspective view showing the spacer of FIG. 1 in use in a mould for a cementitious structure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to the annexed drawings the preferred embodiments of the present invention will be herein described for indicative purpose and by no means as of limitation.

Referring to FIGS. 1 and 2, there is shown an embodiment of a cage spacer, shown generally as 10, in accordance with the present invention. The spacer 10 consists of a bracket, shown generally as 12, having generally first and second opposed side frames, shown generally as 18, preferably identical. The side frames 18 each have a, preferably straight, bottom side 24 and a generally opposed top side 26, the sides 24, 26 of each side frame 18 being connected to one another at longitudinally opposed frame ends 20 by a vertically extending side connecting member 28, as well as by a plurality of spaced apart side connecting members 28 extending therebetween and which connect the bottom and top sides 24, 26 of each side frame 18.

The frames 18 are, in turn, connected to one an other by a plurality of spaced apart frame connecting members 22 extending between and connecting the top sides 26 and bottom sides 24, with the exception of a central portion of the frames 18, where a cylindrically shaped side socket 30 is formed in, preferably centrally situated, side mounting wall 50 of each side frame 18. The bottom sides 24 and horizontal members 22 extending therebetween define a, preferably straight and planar, attachment side or face 16 for the bracket 12, whereas the top sides 26 and horizontal members 22 extending therebetween form an outer roller side or face 14 for the bracket 12, disposed generally opposite the attachment face 16.

As shown in FIGS. 1 and 2, the first and second side sockets 30 are axially aligned with one another along axis X and house a cylindrically shaped roller wheel, shown generally as 32, mounted therein. Specifically, the first and second side sockets 30 are disposed in the side wall 50 of each side frame 18. The side mounting wall 50 extends from the top side 26 downwardly to the bottom of the side socket 30 and, preferably, therebeyond to the bottom side 24. Preferably the top side 26 slopes upwardly, again preferably in a central portion of the bracket 12, towards the side mounting wall 50, such that each side mounting wall 50 is elevated relative the longitudinal ends 20. Thus, the top side 26 is relatively further spaced apart from the bottom side 24 at the side mounting wall 50 compared to the frame ends 20.

The frame and side connecting members 22, 28 advantageously reinforce the bracket 12 and help to prevent compression or deformation thereof during use of the spacer 10.

Referring now to FIGS. 1 through 4, the roller wheel 32 consists of centrally situated inner cylinder 34 and an outer cylinder 36 connected to the inner cylinder 34 by radial support members or arms 38 extending therebetween. The inner cylinder 34 extends axially along axis X through outer cylinder 36 and slightly beyond the radial support arms 38 and the outer cylinder 36 on both wheel sides, shown generally as 44, of the roller wheel 32, Thus, the inner cylinder extends slightly beyond the outer cylinder ends 40 of the outer cylinder 36 and the arm end 42 of the radial support arms 38, which together form the wheel sides 44, and into the side sockets 30.

The inner cylinder 34 extends into the side sockets 30 when the roller wheel 32 is mounted in the bracket 12 and provides the rotatable mounting of the wheel 32. The inner cylinder 34 is of slightly lesser circumference than the side sockets 30, and is thus sized and shaped to be freely rotatable in the side sockets 30 while loosely abutting an inner socket surface of each side socket 30. Advantageously, this loose abutment of the side socket 30 against inner socket surface allows free rotation of the roller wheel 12 in the side sockets 30 while promoting stability of the roller wheel 32 by reducing wobbling of the roller wheel 32 in the side sockets 30. At the same time, the radial support arms 38 provide reinforcement of the wheel 32 when the spacer 10 is placed with in the forming structure 54, shown as mould 54 in FIGS. 3 and 4, with the reinforcement structure 56, shown as cage 56, and helps ensure that the wheel 32 is not squashed or compressed during use, which could compromise the spacing between the reinforcement structure 56 and the forming structure 54.

The respective thickness T1 of the radial support arms 38 and the outer cylinder 36 between the wheel sides 44 is less than the distance D1 between the respective interior sides 46 of the support frames 18. Thus, the side frames 18 are spaced slightly further apart between respective interior sides 46 than a thickness of the radial support arms 38 and the outer cylinder 36. Accordingly, the roller wheel 32 is sized and shaped such that when it is housed in the side sockets 30, it may rotate freely without being obstructed by the side frames 18. Similarly, the radius R1 of the roller wheel 32 is less than the vertical distance D2 between the centre of the side socket 30 and the frame connecting members 22 extending between the bottom sides 24 of the side frames 18. Accordingly, the wheel 32 is also sized and shaped such that when it is mounted in the side socket 30 it may freely rotate without obstruction by the frame connecting members 22 extending between the bottom sides 24 of the side frames 18. The distance between the side mounting walls 50 at the interior sides 46 is, preferably slightly, less than the thickness of the inner cylinder 34 extending between inner cylinder ends 52 thereof. Thus, the inner cylinder 34 is retained in the sockets 30 to prevent unwanted dislodging of the inner cylinder 34 from side sockets 30.

Referring still to FIGS. 1 through 4, the roller wheel 32 is further sized and shaped, with regard to the radius R1 thereof, such that an outer circumferential portion of the outer circumferential surface 64 of the wheel 32, notably of the outer cylinder 36, extends beyond the top side 26 when the wheel 32 is mounted in side sockets 30 of the bracket 12. Thus, the outer circumferential surface 64 extends from within the bracket 12 beyond the roller face 14.

When the spacer 10 is connected to the reinforcement structure 56, typically with the frame connecting members 22 of the attachment face 16 abutting against the reinforcement structure 56, the reinforcement structure 56 can be inserted into the forming structure 54 with the roller wheel 32, specifically the outermost point of the circumferential surface 64 against the forming surface 58 of the forming structure 54. As the roller wheel 32 is freely rotatable in the side sockets 30, the reinforcement structure 56 can be rolled on the wheel 12 into the forming structure 54. At the same time, the spacer 12 maintains the reinforcement structure 56, or the portion thereof supported thereby, spaced apart from the forming surface 58 at a distance D3 equal to the distance between the attachment face 16 and the point of contact, situated on the outer circumferential surface 64, of the wheel 32 and the forming surface 58. Thus, by providing a rolling wheel 32 of appropriate radius, which determines the circumference thereof, and a bracket 12 having the sockets at a desired distance from the attachment face 16, a spacing of the cage 56 at a desired predetermined distance from the forming surface 58 can be provided.

The bracket 12, and in particular the side mounting walls 50, are constructed of a sturdy, but slightly resilient plastic, such that the frames 18, and in particular the side mounting walls 50 are slightly outwardly and resiliently movable to provide removable insertion of said roller wheel into said side sockets between the side mounting walls 50. To further facilitate mounting or seating of the roller wheel 32 in the side sockets 30, the bracket 12 has, preferably centrally situated, guide indentations 48 extending into the side mounting wall 50 in each side frame 18, from the top side 26 down to the side socket 30. The guide indentation 48 is of similar, but slightly greater, width than the outer circumference of the inner cylinder 34. Further, the guide indentations 48 are recessed into the interior of the side mounting wall 50 such that the inner cylinder 34 may be slid or pushed into the indentations 48 with the inner cylinder ends 52 disposed proximal and possibly abutting the interior of the side mounting wall 50 in the indentations 48. Thus, roller wheel 32 may be mounted in the side sockets 30 by positioning the roller wheel 32 with the inner cylinder ends 52 aligned with guide indentations 48 and then forcing or wedging the roller wheel 32 towards side sockets 30 with the inner cylinder ends 52 engaged in the indentations 32. As the inner cylinder 34 is inserted in the indentations 48 towards the side socket 30, the side mounting walls 50 are biased or forced slightly away from one another, until the inner cylinder 34, and notably the ends 52 thereof, are housed, i.e. snap into, the side sockets 30. At this point, the walls 50 bias back towards one another due to the rigid nature of the plastic. To remove the roller wheel 30, the side walls 50 need only be slightly pulled apart from one another and the inner cylinder 34 moved away from the side sockets 30 through the guide indentations 48 until the wheel 32 is removed.

As one skilled in the art will appreciate, the ability to easily insert and remove the roller wheel 32 presents a number of advantages over the prior art. For example, one may easily replace defective roller wheels 32. Additionally, one may choose and install roller wheels 32 of differing radii, and therefore differing circumferences, to adjust the amount of spacing provided to a desired predefined distance for the reinforcement structure 56 from the forming surface 58, while still using a common bracket 12. Additionally, all components of the spacer 10 are made of a solid plastic material, resistant to erosion or damage by cementitious materials such as concrete and cement which form the cementitious structure in the forming structure 54.

Reference is now made to FIGS. 1 though 5. In use, after determining the predefined distance for the desired spacing of the reinforcement structure 56 from the forming surface 58, a roller wheel 32 of appropriate circumference and bracket 12 of appropriate size are selected and the roller wheel 32 is mounted in the side sockets 30 through the guide indentations 48. The bracket 12, preferably the frame connecting members 22 of the attachment face 16, is attached to the cage 56, as shown in FIGS. 3, 4, and 5, preferably with the attachment face 16 extending along and preferably abutting the reinforcement structure 56. For example, the bracket 12 may be tied to the reinforcement structure 56 with wires 60, the wires 60 being tied around one or more of the frame connecting members 22 of the attachment face 16 and the reinforcement structure 56. Preferably, and as shown in FIGS. 3 and 5, a plurality of spacers 10 are so attached, spaced apart from one another around the perimeter of the reinforcement structure 56, which is preferably of similar shape to the forming surface 58. For example, and as shown, for a cylindrical reinforcement structure 56, i.e. cage 56, and forming structure 54, i.e. mould 54, spacers 10 are attached spaced apart from one another at various positions on the circumference of the cage 56. However, it should be noted that the spacer 10 may be used with any shape of reinforcement structure 56 and forming structure 54, provided that the spacing/distribution of the spacers 10 is such that the desired predefined distance of spacing for the reinforcement structure 56 relative the forming surface 58 of the forming structure 54 is maintained and that the reinforcement structure 56 can be rolled into the forming structure 54 on the spacers 10.

Once the spacers 10 have been attached, the reinforcement structure 56 is rolled thereupon into the forming structure 54. The cementitious material is then poured into the reinforcement structure 56 to form the cementitious structure. It should be further noted that spacers 10 could also be attached with the outer face 14 facing inwardly from the reinforcement structure 56 towards an outer forming surface of inner forming structure, not shown, positioned inside the reinforcement structure 56 for spacing the reinforcement structure 56 at a desired distance from the inner forming structure. The cementitious material may be any material commonly used for forming cementitious structures, including cement, concrete, asphalt, or the like.

Although the present invention has been described with a certain degree of particularity, it is to be understood that the disclosure has been made by way of example only and that the present invention is not limited to the features of the embodiments described and illustrated herein, but includes all variations and modifications within the scope and spirit of the invention as hereinafter claimed. 

1. A cage spacer for spacing a reinforcement structure apart at a predefined distance from a forming surface of a forming structure for a cementitious structure during formation of the cementitious structure therein, the spacer comprising: a bracket having an attachment face and a generally opposed roller face, said bracket being connectable to said reinforcement structure with said attachment face abutting thereagainst; and a cylindrically shaped roller wheel rotatably mounted in said bracket with an outer circumferential surface thereof extending from within said bracket partially beyond said roller face, said roller wheel being sized and positioned relative said attachment face for abutting and rolling of said outer circumferential surface against said forming surface at said predefined distance from said reinforcement structure, thereby spacing said reinforcement structure apart from said forming surface at said predefined distance and enabling rolling of said reinforcement structure into said forming structure at said predefined distance from said forming surface, said bracket and said roller wheel being constructed of a plastic material.
 2. The cage spacer of claim 1, wherein said roller wheel is removably mounted in said bracket.
 3. The cage spacer of claim 1, wherein said attachment face is generally straight.
 4. The cage spacer of claim 1, wherein said bracket is comprised of generally opposed first and second side frames, said side frames being connected to one another and each side frame having a generally straight bottom side and a generally opposed top side.
 5. The cage spacer of claim 4, wherein each side frame comprises a plurality of spaced apart vertically extending side connecting members connecting said top side to said bottom side and, at respectively longitudinally opposed frame ends of said side frame, one said side connecting member for each frame end connecting said bottom side to said top side.
 6. The cage spacer of claim 5, wherein said side frames are connected to one another by a plurality of frame connecting members, said frame connecting members extending from one said top side to the other and from one said bottom side to the other, said top sides and said frame connecting members extending therebetween defining said roller face, said bottom sides and said frame connecting members extending therebetween defining said attachment face.
 7. The cage spacer of claim of claim 4, wherein said bracket comprises generally opposed and aligned first and second side sockets, one side socket on each side frame, said roller wheel being rotatably mounted in said side sockets.
 8. The cage spacer of claim 7, wherein said side sockets are generally centrally situated between said frame ends.
 9. The cage spacer of claim 7, wherein said side sockets are cylindrically shaped.
 10. The cage spacer of claim 9, wherein said roller wheel comprises a centrally situated inner cylinder and an outer cylinder connected to said inner cylinder, said inner cylinder extending through said outer cylinder and said outer circumferential surface extending around said outer cylinder.
 11. The cage spacer of claim 10, wherein said roller wheel further comprises a plurality of spaced apart radial support arms extending radially from said inner cylinder to said outer cylinder.
 12. The cage spacer of claim 10, wherein said inner cylinder extends beyond said outer cylinder and radial support arms on opposing wheels sides of said roller wheel and into said side sockets to mount said roller wheel therein, said inner cylinder being freely rotatable in said side sockets while abutting, in each side socket, a respective inner socket surface.
 13. The cage spacer of claim 12, wherein said side frames are spaced slightly further apart between respective interior sides thereof than a thickness of said radial support arms and said outer cylinder between said wheel sides, said roller wheel being thereby freely rotatable without being obstructed by said side frames when mounted in said side sockets.
 14. The cage spacer of claim 12, wherein a radius of said roller wheel is less than a vertical distance from a centre of each side socket to said frame connecting members, said roller wheel being thereby freely rotatable without being obstructed by said frame connecting members when mounted in said side sockets.
 15. The cage spacer of claim 13, wherein each said bracket comprises generally opposed and aligned first and second side mounting walls, each side frame having one said side mounting wall extending from said top side downwardly to said bottom side, said side socket being formed in said mounting wall.
 16. The cage spacer of claim 15, wherein, for each side frame, said top side in proximity to said side mounting wall slopes outwardly away relative said bottom side and towards said side mounting wall, said top side being relatively further spaced apart from said bottom side at said side mounting wall than at said frame ends.
 17. The cage spacer of claim 13, wherein said side sockets and said side mounting walls are generally centrally situated between said frame ends.
 18. The cage spacer of claim 14, wherein respective inner cylinder ends between which said inner cylinder extends are spaced slightly further apart than said side mounting walls at said interior surface for retaining inner cylinder in said side sockets.
 19. The cage spacer of claim 18, wherein said side mounting walls are slightly outwardly and resiliently movable for removable insertion of said roller wheel into said side sockets between said side mounting walls.
 20. The cage spacer of claim 19, wherein said side mounting walls comprise guide indentations extending on said interior side from said top side to said side socket, one said guide indentation for each side mounting wall, said inner cylinder being insertable from said top side through said guide indentations with said inner cylinder ends biasing said side mounting walls resiliently outwardly until said inner cylinder is seated in said side sockets. 